Optical fiber fan-out device for a furcation tube assembly

ABSTRACT

The present disclosure relates to an optical fiber fan-out device having a furcation tube assembly. The furcation tube assembly includes a furcation tube mounting insert and an array of furcation tubes. The first end of the furcation tube mounting insert has a first end surface being a slant configuration at an oblique angle relative to the furcation tube axes. The slanted edge helps to insert optical fibers into the furcation tubes. The supported portions of the furcation tubes have fiber insertion ends that terminate at the first end surface. The furcation tubes also including free portions that extend from the second end of the furcation tube mounting insert.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of application Ser. No. 13/957,880,filed Aug. 2, 2013, now issued as U.S. Pat. No. 8,958,672,whichapplication claims the benefit of U.S. Provisional Patent ApplicationSer. No. 61/679,268, filed Aug. 3, 2012, which applications areincorporated herein by reference in their entirety.

TECHNICAL FIELD

The present disclosure relates to fiber fan-out devices used in fiberoptic networks.

BACKGROUND

In a fiber optic telecommunication network, a fan-out device is used todistribute optical fibers from a multi-fiber cable or tube containingmultiple fibers to a plurality of individual furcation tubes. Fan-outdevices are disclosed at, for example, U.S. Pat. No. 7,461,981 to Yow,Jr. et al., U.S. Pat. No. 6,816,663 to Daoud and U.S. Pat. No. 6,061,492to Strause et al.

SUMMARY

The present disclosure relates to an optical fiber fan-out device havinga furcation tube assembly. The furcation tube assembly includes afurcation tube mounting insert and an array of furcation tubes. Thefurcation tubes have supported portions secured within the furcationtube mounting insert. The supported portions of the furcation tubesdefine parallel furcation tube axes. The first end of the furcation tubemounting insert has a first end surface that is slanted at an obliqueangle relative to the furcation tube axes. The slanted edge helps toinsert optical fibers into the furcation tubes. The supported portionsof the furcation tubes have fiber insertion ends that terminate at thefirst end surface. The furcation tubes also including free portions thatextend outwardly from the second end of the furcation tube mountinginsert.

A variety of additional aspects will be set forth in the descriptionthat follows. The aspects relate to individual features and tocombinations of features. It is to be understood that both the foregoinggeneral description and the following detailed description are exemplaryand explanatory only and are not restrictive of the broad inventiveconcepts upon which the embodiments disclosed herein are based.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top, perspective view of a furcation tube assembly inaccordance with the principles of the present disclosure;

FIG. 2 is a perspective view of the furcation tube assembly of FIG. 1;

FIG. 3 is an exploded view of the furcation tube assembly of FIG. 1;

FIG. 4 is an exploded view of a fan-out module in accordance with theprinciples of the present disclosure;

FIG. 5 is an assembled, perspective view of the fan-out module of FIG.4;

FIG. 6 is a top plan view of a fan-out module showing the furcation tubeassembly with optical fibers routed through the fan-out module;

FIG. 7 is another perspective view of the fan-out module of FIG. 4 withthe furcation tube assembly loaded in the fan-out module and a top coverof the fan-out module removed;

FIG. 8 is a cross-sectional view taken along section line 8-8 of FIG. 6;

FIG. 9 is a fiber insertion end view of the furcation tube assembly ofFIG. 1;

FIG. 10 is a perspective view of a fan-out module in a stackarrangement;

FIG. 11 is a perspective view of one of the furcation tubes of thefurcation tube assembly of FIG. 1;

FIG. 12 is another perspective view of one of the furcation tubes of thefurcation tube assembly of FIG. 1;

FIG. 13 is a perspective view of the end face of the furcation tube ofFIGS. 11 and 12; and

FIG. 14 is another perspective view of the end face of the furcationtube of FIGS. 11 and 12.

DETAILED DESCRIPTION

Various embodiments will be described in detail with reference to thedrawings, wherein like reference numerals represent like parts andassemblies throughout the several views. Reference to variousembodiments does not limit the scope of the claims attached hereto.Additionally, any examples set forth in this specification are notintended to be limiting and merely set forth some of the many possibleexamples of how inventive aspects in accordance with the principles ofthe present disclosure may be embodied.

Referring to FIGS. 1-3, an optical fiber fan-out device 100 having afurcation tube assembly 10 in accordance with the principles of thepresent disclosure is illustrated. The furcation tube assembly 10includes a furcation tube mounting insert 12 and an array of furcationtubes 14. The furcation tube mounting insert 12 includes a first end 16and a second end 18 positioned opposite from the first end 16. Thefurcation tube mounting insert 12 also includes a first side 20 and asecond side 22 positioned opposite from the first side 20. The furcationtube assembly 10 has a length L1 that extends between the first end 16and the second end 18 of the furcation tube mounting insert 12. Thefirst and second sides 20, 22 of the furcation tube mounting insert 12extend along the length L1 of the furcation tube mounting insert 12. Thefurcation tube assembly 10 also includes a width W1 that extends betweenthe first side 20 and the second side 22 of the furcation tube mountinginsert 12. The width W1 of the furcation tube mounting insert 12 isperpendicular relative to the length L1 of the furcation tube mountinginsert 12.

The furcation tubes 14 of the furcation tube assembly 10 can havesupported portions 24 and free portions 30. The free portions 30 of thefurcation tubes 14 may extend outwardly from the second end 18 of thefurcation tube mounting insert 12. The free portions 30 may have alength greater than 2 feet. Of course, other lengths can be used as wellto fit particular applications. The supported portions 24 may be securedwithin the furcation tube mounting insert 12 (e.g., by an adhesivematerial or mechanically by friction or other means). The furcation tubemounting insert 12 can include a first piece 42 and a second piece 44.The supported portions 24 are arranged and configured to be securedbetween the first and second pieces 42, 44 of the furcation tubemounting insert 12. As shown, the first and second pieces 42, 44 of thefurcation tube mounting insert 12 can be arranged and configured so asto cooperate to define the first end 16, the second end 18, the firstside 20, and the second side 22 of the furcation tube mounting insert12.

The supported portions 24 may define furcation tube axes 26 within thefurcation tube mounting insert 12. The furcation tube mounting insert 12may define parallel, inferior grooves 25 for receiving the furcationtubes 14. Half portions of each of the grooves 25 may be formed by thefirst and second pieces 42, 44. As shown, the furcation tube axes 26extend parallel along the length L1 of the furcation tube mountinginsert 12. The furcation tube axes 26 may be aligned along a plane P1(see FIG. 9) extending across the width W1 of the furcation tubemounting insert 12.

In one aspect, the first end 16 of the furcation tube mounting insert 12can include a first end surface 28. The first end surface 28 may extendacross the width W1 of the furcation tube mounting insert 12 between thefirst and second sides 20, 22 of the furcation tube mounting insert 12.As shown, the first end surface 28 slants at an oblique angle θ relativeto the furcation tube axes 26 as the first end surface 28 extends acrossthe width W1 of the furcation tube mounting insert 12. The oblique anglecan be in the range of 15 degrees to 45 degrees. Of course, other anglesare applicable as well. It is understood that other configurations maybe used according to the principles disclosed. The supported portions 24of the furcation tubes 14 can have fiber insertion ends 15 thatterminate at the first end surface 28 of the furcation tube mountinginsert 12. The fiber insertion ends 15 can be aligned generally along aplane P2 that is defined by the first end surface 28 and that is alignedat the oblique angle θ relative to the furcation tube axes 26. The planeP2 is also slanted at an incline angle α (see FIG. 2) relative tohorizontal so that the first end surface 28 generally has a rampedconfiguration.

In another aspect, the second end 18 of the furcation tube mountinginsert 12 can include a second end surface 32. The second end surface 32may extend across the width W1 of the furcation tube mounting insert 12.The second end surface 32 can be perpendicular relative to the furcationtube axes 26. It is understood that other configurations may be utilizedaccording to the principles disclosed.

The furcation tube mounting insert 12 can include a third side 34 and afourth side 36 that is positioned opposite from the third side 34. Thethird and fourth sides 34, 36 can each extend across the width W1 andlength L1 of the furcation tube mounting insert 12 between the first andsecond sides 20, 22 of the furcation tube mounting insert 12. As shown,the first and second sides 20, 22 are minor sides of the furcation tubemounting insert 12 and the third and fourth sides 34, 36 are major sidesof the furcation tube mounting insert 12. The first piece 42 of thefurcation tube mounting insert 12 defines the third side 34 of thefurcation tube mounting insert 12. The second piece 44 of the furcationtube mounting insert 12 defines the fourth side 36 of the furcation tubemounting insert 12. The third side 34 can be considered a top side andthe fourth side 36 can be considered a bottom side.

At least one of the third or fourth sides 34, 36 can define a slot 38.The slot 38 can extend across the width W1 of the furcation tubemounting insert 12. The slot 38 may be slanted at an oblique anglerelative to the furcation tube axes 26. Other configurations can beutilized according to the principles disclosed. UV curable adhesive canbe used to secure the furcation tubes 14 within the furcation tubemounting insert 12. The slot 38 may be used for curing the UV curableadhesive.

The furcation tube mounting insert 12 also has a height h that extendsbetween the third and fourth sides 34, 36. The plane P2 is angledrelative to the third and fourth sides 34, 36 such that the plane P2slants at the angle α toward the second end 18 of the furcation tubemounting insert 12 as the plane P2 (and the corresponding first endsurface 28) extends along the height H from the fourth side 36 (i.e.,the bottom side) to the third side 34 (i.e., the top side). The ends 15of the furcation tubes 14 are angled to coincide with the plane P2 andbe flush with the first end surface 28.

Referring to FIGS. 4-5, a fan-out module 200 is shown. The fan-outmodule 200 includes the optical fiber fan-out device 100 and a fan-outhousing 46. The fan-out housing 46 can include a cable tube end 48 and afurcation tube end 50. Adhesive tape 40 may be used to secure the cabletube 52 to the cable tube end 48 of the fan-out housing 46. The adhesivetape 40 can be placed between the first and second housing pieces 58,60. The first housing piece 58 may have tape anchoring projections 62,as shown in FIG. 7, which puncture through the adhesive tape 40 and fitwithin corresponding openings 61 defined by the second housing piece 60.The adhesive tape 40 may be a double sided adhesive. It is understoodthat other types of adhesives may be used according to the principlesdisclosed. Other types of anchoring techniques such as mechanicalcrimping or clamping can also be used.

The fan-out housing 46 may extend along a length L2 between the cabletube end 48 and the furcation tube end 50. As shown, the fan-out housing46 is arranged and configured for receiving a cable tube 52. Forexample, the cable tube end 48 can define an opening 51 for receivingthe cable tube 52. The furcation tube mounting insert 12 can beconfigured to mount within the fan-out housing 46 such that the firstend 16 of the furcation tube mounting insert 12 is positioned to facetoward the direction of the cable tube end 48 of the fan-out housing 46.The second end 18 of the furcation tube mounting insert 12 is positionedto face toward the direction of the furcation tube end 50 of the fan-outhousing 46. The free portions 30 of the furcation tubes 14 can beconfigured to extend outwardly from the furcation tube end 50 of thefan-out housing 46.

The first and second sides 20, 22 of the furcation tube mounting insert12 each can include notches 54 that can be configured to receive tabs 56of the fan-out housing 46 for interlocking the furcation tube mountinginsert 12 relative to the fan-out housing 46. This interlocking maylimit relative longitudinal movements between the furcation tubemounting insert 12 and the fan-out housing 46. As shown, the tabs 56 arelocated on the second housing piece 60. The number of tabs 56 shown issix. It is understood that any number of tabs 56 can be utilized andpositioned on the fan-out housing 46.

The fan-out housing 46 is depicted as being rectangular in shape and mayinclude a first housing piece 58 and a second housing piece 60. Asshown, the furcation tube mounting insert 12 is mounted between thefirst and second housing pieces 58, 60. The first housing piece 50defines a first major side of the fan-out housing 46 and the secondhousing piece 60 defines a second major side of the fan-out housing 46opposite from the first major side. The first housing piece 58 and thesecond housing piece 60 are arranged and configured together to definethe cable tube end 48 of the fan-out housing 46 and the furcation tubeend 50 of the fan-out housing 46. The first housing piece 58 may includelatches 64 that can be flexible to snap within catches 66 defined by thesecond housing piece 60 to latch the first and second housing pieces 58,60 together. As shown, the latches 64 are arranged and configured on thefirst housing piece 58 and the catches 66 are arranged and configured onthe second housing piece 60. The number of latches 64 and catches 66 aredepicted as being four each. It is understood that the latches 64 andcatches 66 can vary in number and be positioned without departing fromthe principles of the present disclosure.

The fan-out housing 46 can include mounting latches 68 for securing thefan-out housing 46 to another optical component. The mounting latches 68can be located on the first housing piece 58 along the length L2 betweenthe cable tube end 48 and the furcation tube end 50. As shown, thefan-out housing 46 includes two mounting latches 68 positioned atopposite sides of the fan-out housing 46. The number of mounting latches68 and position of the mounting latches 68 may be varied withoutdeparting from the principles of the present disclosure. The fan-outhousing 46 may be stacked together using mounting latch receptacles 70located in the fan-out housing 46. As shown in FIG. 10, the mountinglatch receptacles 70 can receive the mounting latches 68 of anotherfan-out housing 46 to secure the fan-out housings 46 in a stackedrelationship.

Referring now to FIG. 6, the cable tube 52 is shown with optical fibers72 routed from the cable tube 52 through the fan-out module 200. Theoptical fibers 72 may be inserted from the cable tube 52 into thefurcation tubes 14 at the first surface end 28 of the furcation tubemounting insert 12. The slanting of the first end surface 28 of thefurcation tube mounting insert 12 along the angle θ can help to insertthe optical fibers 72 inside the furcation tubes 14. Specifically, theinsertion ends 15 of the furcation tubes 14 are positioned atprogressively longer longitudinal spacings S from the cable tube end 48of the fan-out housing 46. The furcation tubes 14 can include twelvefurcation tubes 14 a-14 l. The insertion end 15 of the furcation tube 14a defines the shortest spacing and the insertion end 15 of the furcationtube 14 l defines the longest spacing. The furcation tube 14 a is ingeneral co-axial alignment with the cable tube 52 while the furcationtubes 14 b-14 l are progressively laterally offset from the cable tube52. The slanted configuration of the insertion ends 15 of the furcationtubes 14 a-14 l facilitates inserting optical fibers into the insertionends 15 and also enhances fiber routing and bend radius protectionwithin the fan-out housing 46. The slanting of the insertion ends 15 ofthe furcation tubes 14 along the angle α also assists in insertingfibers in the furcation tubes 14 because t portions of the furcationtubes 14 are cut-away at the insertion ends 15 thereby providingenhanced access to the interiors of the furcation tubes 14 from above.

The optical fibers 72 extend through the furcation tubes 14 and mayinclude free ends that are connectorized (e.g., see connectors 300) ormay be adopted to be spliced to another fiber. As shown, there aretwelve furcation tubes 14. The furcation tubes 14 can be about 900microns in outer diameter and each furcation tube 14 include a singleoptical fiber 72, as shown in FIG. 8. The optical fiber 72 can becoated. It is understood that there may be more or less furcation tubes14 that can be utilized according to principles disclosed. In certainembodiments, the fibers 72 can have cores of about 8-12 microns,cladding layers of about 120-130 microns in outer diameter, and coatinglayers of about 240-260 microns in outer diameter. Other fiberconstructions can be used as well.

FIGS. 11 and 12 show one of the furcation tubes 14 of the furcation tubeassembly 10 of FIG. 1. The fiber insertion end 15 of the furcation tube14 includes an end face 400 that is oriented/slanted at an oblique anglerelative to the central longitudinal axis 26 of the furcation tube 15.The angling of the end face 400 can be provided by cutting, etching,forming, molding, scoring or otherwise shaping the fiber insertion end15. The oblique angle is preferably a compound angle including a miterangle/component x and a bevel angle/component y. The miter angle x isdefined relative to a horizontal axis 402 that is perpendicular relativeto the central longitudinal axis 26. The bevel angle y is definedrelative to a vertical axis 404 that is perpendicular to the centrallongitudinal axis 26. In certain embodiments, both the miter angle x andthe bevel angle y can be in the range of 15-45 degrees. In certainembodiments, the furcation tube has an outer diameter in the range of600-1200 microns or in the range of 800-1000 microns, and an innerdiameter larger than 240 microns. In other embodiments, the miter andbevel angles can be outside of the range specified above.

The various embodiments described above are provided by way ofillustration only and should not be construed to limit the claimsattached hereto. Those skilled in the art will readily recognize variousmodifications and changes that may be made without following the exampleembodiments and applications illustrated and described herein, andwithout departing from the true spirit and scope of the disclosure.

What is claimed is:
 1. A method of cabling a fanout module including afanout housing and a furcation tube mounting insert, the furcation tubemounting insert having first and second pieces defining grooves thatcooperate to support portions of furcation tubes, the furcation tubemounting insert having a slanted end such that insertion ends of thefurcation tubes are positioned at progressively longer longitudinalspacings from an end of the fanout housing, the method comprising:routing a cable tube to the slanted end of the furcation tube mountinginsert, the cable tube holding a plurality of optical fibers; insertingthe optical fibers into the insertion ends of the furcation tubes; anddisposing the furcation tube mounting insert within the fanout housing.2. The method of claim 1, wherein routing the cable tube to the slantedend comprises routing the cable tube so that the cable tube is coaxialwith one of the furcation tubes supported by the furcation tube mountinginsert.
 3. The method of claim 2, wherein the furcation tubes aredisposed in a single row between the first and second pieces, andwherein the furcation tube with which the cable tube is coaxial islocated at a far end of the single row.
 4. The method of claim 1,wherein free ends of the optical fibers are connectorized.
 5. The methodof claim 1, wherein free ends of the optical fibers are configured to bespliced to other fibers.
 6. The method of claim 1, wherein eachfurcation tube is sized to hold a single optical fiber.
 7. The method ofclaim 1, wherein routing the cable tube to the slanted end of thefurcation tube mounting insert comprises inserting the cable tube intoan opening defined by the fanout housing.
 8. The method of claim 1,wherein disposing the furcation tube mounting insert within the fanouthousing comprises interlocking the furcation tube mounting insert andthe fanout housing.
 9. The method of claim 8, wherein interlocking thefurcation tube mounting insert and the fanout housing comprisesinserting tabs of the fanout housing into notches defined by thefurcation tube mounting insert.
 10. The method of claim 1, whereindisposing the furcation tube mounting insert within the fanout housingcomprises mounting the furcation tube mounting insert between the firstand second pieces of the fanout housing.
 11. The method of claim 10,wherein mounting the furcation tube mounting insert between the firstand second pieces of the fanout comprises snapping latches of the firstpiece within catches of the second piece.
 12. The method of claim 1,further comprising limiting relative longitudinal movements between thefurcation tube mounting insert and the fan-out housing.
 13. The methodof claim 1, wherein inserting the optical fibers into the insertion endsof the furcation tubes comprises: inserting a first optical fiber into afirst of the furcation tubes that is coaxial with the cable tube; andinserting a second optical fiber into a second of the furcation tubesthat is laterally offset from the first furcation tube, wherein theinsertion end of the second furcation tube is axially offset from theinsertion end of the first furcation tube.
 14. The method of claim 13,wherein inserting the optical fibers into the insertion ends of thefurcation tubes further comprises inserting a third optical fiber into athird of the furcation tubes that is laterally offset from the secondfurcation tube, wherein the insertion end of the third furcation tube isaxially offset from the insertion end of the second furcation tube.